Rapid interior wall layout components and methods

ABSTRACT

A rapid interior wall layout system can include an anchor and clasp. The anchor can have a lower portion that fits within a drywall track opening, an upper portion having an external notch, and a central opening that extends through the lower and upper portions to receive a fastener that extends through the anchor to hold the anchor in place against an existing building structure. The clasp can include a base, arms pivotally coupled to the base, tabs that extend inward from the arms, and flanges that extend from the base and arms. The clasp tabs can lock onto the external notch during installation to hold the drywall track in place against the anchor. The system can also include the drywall track itself, a second anchor for a second opening in the drywall track and a second clasp to hold the drywall track in place against the second anchor.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional PatentApplication No. 62/835,403 filed on Apr. 17, 2019 and entitled“COMPONENTS AND METHODS FOR RAPID LAYOUT OF INTERIOR WALLS,” whichapplication is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to building construction, andmore particularly to the layout and installation of interior wallsduring building construction.

BACKGROUND

Building construction often involves forming interior walls using lightgauge steel framing components. Metal frame walls can include “drywalltracks” that run horizontally along the foot and head of the wall, aswell as “studs” that are spaced apart and positioned vertically betweenthe tracks. To prepare for interior partition wall framing, carpenterstypically engage in a layout process that requires many steps. Forexample, a carpenter may iteratively read room dimensions from a floorplan drawing, transfer those measurements to the floor, snap chalk lineson the floor along the edge of each wall according to the floor plan,transfer those chalk lines to structural elements in the ceiling, aligntop track segments to their intended positions on the ceiling, andsecure the top track segments to the structure using powder-actuatedfasteners. It is critical to perform this wall layout accurately, asplumbers, electricians, and other construction trades depend onaccurately positioned walls, and small deviations from floor plandrawings can cause a series of cascading issues in the construction ofthe building.

Some carpenters have recently adopted digital tools that improve thespeed and accuracy of wall layout. One such tool is the robotic totalstation, which uses electronic transit theodolites in conjunction withan electronic distance meter to read a slope distance from the stationto a given spot. This allows carpenters to quickly and accurately locatecritical wall vertices along a floor, such as at corners andintersections. Many manual tasks remain, however, such as snapping chalklines between critical vertices, transferring those chalk lines to aceiling, and aligning top tracks to layout marks for fastening. Removingthese tasks from the layout process would bring significant productivitygains.

Although traditional ways of forming interior walls during buildingconstruction have worked well in the past, improvements are alwayshelpful. In particular, what is desired are systems and methods thateliminate steps from the interior wall layout process without losingaccuracy in wall placement.

SUMMARY

It is an advantage of the present disclosure to provide buildingconstruction components that reduce time and effort from the interiorwall layout process. The disclosed features, apparatuses, systems, andmethods provide improved interior wall layout solutions that caneliminate at least the steps of creating measurement lines along afloor, snapping related chalk lines along the edge of a wall, andtransferring those chalk lines to structural elements in a ceiling,without losing any accuracy in final wall placement. These advantagescan be accomplished at least in part by providing anchors and customizedconstruction components having clasps that lock onto installed anchors.

In various embodiments of the present disclosure, an anchor configuredfor rapid construction can include at least a lower portion, an upperportion, and a central opening. The lower portion can be configured tocouple with an existing building structure and can include a bottomsurface to contact the existing building structure and one or moreexterior surfaces that fit within an opening in a separate constructioncomponent, such as a drywall track. The construction component can alsobe a pipe hanger, a duct hanger, a cable tray hanger, or any otherconstruction component suitable for having the various featuresdisclosed herein or extrapolations thereof. The upper portion can belocated proximate the lower portion and can include a top surface and anexternal notch configured to receive a separate clasp that holds theseparate construction component in place against the anchor. The centralopening can extend through the lower and upper portions and can beconfigured to receive a fastener that extends through the anchor andinto the existing building structure to hold the anchor in place againstthe existing building structure.

In various detailed embodiments, the upper portion of the anchor can beintegrally formed with the lower portion, and the entire anchor can besymmetrical about a longitudinal axis that extends through the length ofthe central opening. The central opening can have a firstcross-sectional diameter at the lower portion and a secondcross-sectional diameter at the upper portion that is larger than thefirst cross-sectional diameter. In some arrangements, thecross-sectional diameter of the central opening can linearly decrease insize through at least part of the upper portion, and the anchor can beconfigured to receive a fastening force from the fastener at innersurfaces of the central opening where the cross-sectional diameter ofthe central opening linearly decreases in size. Alternatively, or inaddition, the anchor can be configured to receive a fastening force fromthe fastener at the top surface of the upper portion. The fastener canbe a powder-actuated fastener, among other possible fasteners, and maybe combined with the anchor to form a single component. In addition, theexternal notch can define an annular groove that extends around theouter circumference of the upper portion. In some arrangements, at leastpart of the central opening can include an internal thread configured tomate with the fastener. This can be particularly useful where the anchorand fastener are combined as a single component prior to installation.

In various further embodiments of the present disclosure, a systemconfigured for rapid construction can include at least a constructioncomponent and a first clasp. The system can also include a second clasp.The construction component can have a first opening, and the first claspcan be coupled to the construction component, arranged around the firstopening, and configured to lock onto a first external notch of a firstanchor to hold the construction component in place against the firstanchor. The construction component can also include a second opening,and the second clasp can similarly be coupled to the constructioncomponent, arranged around the second opening, and configured to lockonto a second external notch of a second anchor to hold the constructioncomponent in place against the second anchor.

In various detailed embodiments, the first clasp can include a base, afirst arm pivotally coupled to a first distal end of the base, and asecond arm pivotally coupled to a second distal end of the base oppositethe first distal end. The first arm and second arm can be configured topivot outward when the first clasp is fitted over the top surface of theupper portion of the first anchor and to pivot back inward when thefirst clasp locks onto the first external notch. The first clasp canfurther include tabs extending inward from both of the first and secondarms, as well as flanges that extend laterally from the base, the firstarm, and the second arm. The tabs can lock into the first external notchwhen the first and second arms pivot back inward, and the flanges caninclude openings configured to receive fastening components that affixthe first clasp to the construction component. The constructioncomponent can be a drywall track, but could also be a pipe hanger, aduct hanger, or a cable tray hanger. Further system arrangements caninclude the first and second anchors.

In still further embodiments, various methods of attaching aconstruction component to an existing building structure are provided.Method steps can include forming a first opening in the constructioncomponent and coupling a first clasp to the construction component withone or more fastening components such that the first clasp is arrangedaround the first opening, wherein the first clasp is configured to lockonto a first external notch of a first anchor and hold the constructioncomponent in place against the first anchor. Method steps can alsoinclude forming a second opening in the construction component, andcoupling a second clasp to the construction component with one or morefastening components such that the second clasp is arranged around thesecond opening, wherein the second clasp is configured to lock onto asecond external notch of a second anchor and hold the constructioncomponent in place against the second anchor. Further method steps caninclude locating a first point along an existing building structureusing a robotic total station, attaching the first anchor to theexisting building structure at the first point with a first fastener,locating a second point along the existing building structure using therobotic total station, attaching the second anchor to the existingbuilding structure at the second point with a second fastener, andinstalling the construction component onto the first and second anchors.The anchors can include the same features detailed above, and theinstalling step can involve the first clasp locking onto the firstexternal notch to hold the first clasp and construction component inplace against the first anchor and the existing building structure, andcan also involve the second clasp locking onto the second external notchto hold the second clasp and construction component in place against thesecond anchor and the existing building structure. The fasteningcomponents can include rivets that affix the clasps to the constructioncomponent, which can be a drywall track, pipe hanger, duct hanger, orcable tray hanger.

Other apparatuses, methods, features, and advantages of the disclosurewill be or will become apparent to one with skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional apparatuses, methods, features andadvantages be included within this description, be within the scope ofthe disclosure, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The included drawings are for illustrative purposes and serve only toprovide examples of possible structures and arrangements for thedisclosed apparatuses, systems and methods for the rapid layout ofinterior walls. These drawings in no way limit any changes in form anddetail that may be made to the disclosure by one skilled in the artwithout departing from the spirit and scope of the disclosure.

FIG. 1A illustrates in top perspective view exemplary anchor locationsalong a substrate plane as determined by a robotic total stationpositioned on a floor according to one embodiment of the presentdisclosure.

FIG. 1B illustrates in top perspective view an exemplary drywall trackconfigured to mount to anchors at the anchor locations according to oneembodiment of the present disclosure.

FIG. 2A illustrates in front perspective view an exemplary anchorconfigured for rapid construction according to one embodiment of thepresent disclosure.

FIG. 2B illustrates in side elevation view the anchor of FIG. 2Aaccording to one embodiment of the present disclosure.

FIG. 2C illustrates in top plan view the anchor of FIG. 2A according toone embodiment of the present disclosure.

FIG. 2D illustrates in side cross section view the anchor of FIG. 2Aaccording to one embodiment of the present disclosure.

FIG. 2E illustrates in side cross section view an exemplary alternativeanchor according to one embodiment of the present disclosure.

FIG. 3A illustrates in front perspective view an exemplary clasp for usewith a drywall track according to one embodiment of the presentdisclosure.

FIG. 3B illustrates in front elevation view the clasp of FIG. 3Aaccording to one embodiment of the present disclosure.

FIG. 3C illustrates in top plan view the clasp of FIG. 3A according toone embodiment of the present disclosure.

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FIG. 3D illustrates in side elevation view the clasp of FIG. 3Aaccording to one embodiment of the present disclosure.

FIG. 4A illustrates in front perspective view an exemplary drywalltrack.

FIG. 4B illustrates in top plan view the drywall track of FIG. 4A.

FIG. 4C illustrates in top plan view an exemplary drywall track modifiedto have two openings formed therein according to one embodiment of thepresent disclosure.

FIG. 5A illustrates in top perspective view an assembled combinationincluding the modified drywall track of FIG. 4C with two clasps attachedaround the two openings according to one embodiment of the presentdisclosure.

FIG. 5B illustrates in top plan view the assembled combination of FIG.5A according to one embodiment of the present disclosure.

FIG. 5C illustrates in bottom plan view the assembled combination ofFIG. 5A according to one embodiment of the present disclosure.

FIG. 6A illustrates in front perspective view an exemplary clasp priorto locking onto an anchor according to one embodiment of the presentdisclosure.

FIG. 6B illustrates in front perspective view an exemplary clasp afterlocking onto an anchor according to one embodiment of the presentdisclosure.

FIG. 7 illustrates in top perspective view the modified drywall track ofFIG. 5A after installation onto two anchors according to one embodimentof the present disclosure.

FIG. 8 illustrates in exploded view an exemplary locator pin assemblyaccording to one embodiment of the present disclosure.

FIG. 9 illustrates in elevation view the locator pin assembly of FIG. 8according to one embodiment of the present disclosure.

FIG. 10A illustrates in elevation view the locator pin assembly of FIG.8 as an installer prepares to drive it into a substrate according to oneembodiment of the present disclosure.

FIG. 10B illustrates in elevation view the locator pin assembly of FIG.10A when its bushing top surface impacts a substrate surface accordingto one embodiment of the present disclosure.

FIG. 10C illustrates in elevation view the locator pin assembly of FIG.10A when a pin flat head impacts the bushing causing the pin to stopaccording to one embodiment of the present disclosure.

FIG. 11 illustrates in exploded view an exemplary metal wall trackconfigured to snap over a pair of locator pin assemblies embedded in asubstrate according to one embodiment of the present disclosure.

FIG. 12 illustrates in cross section view the track of FIG. 11 as aninstaller presses the metal wall track over the locator pin assembliesaccording to one embodiment of the present disclosure.

FIG. 13 illustrates in cross section view the track of FIG. 11 whencaptive washers snap past the tips of spring tabs according to oneembodiment of the present disclosure.

FIG. 14 illustrates in front perspective view exemplary locator pinassembly locations along a substrate plane as determined by a robotictotal station positioned on a floor according to one embodiment of thepresent disclosure.

FIG. 15 illustrates a flowchart of an exemplary method of attaching acomponent to an existing building structure according to one embodimentof the present disclosure.

DETAILED DESCRIPTION

Exemplary applications of apparatuses, systems, and methods according tothe present disclosure are described in this section. These examples arebeing provided solely to add context and aid in the understanding of thedisclosure. It will thus be apparent to one skilled in the art that thepresent disclosure may be practiced without some or all of thesespecific details provided herein. In some instances, well known processsteps have not been described in detail in order to avoid unnecessarilyobscuring the present disclosure. Other applications are possible, suchthat the following examples should not be taken as limiting. In thefollowing detailed description, references are made to the accompanyingdrawings, which form a part of the description and in which are shown,by way of illustration, specific embodiments of the present disclosure.Although these embodiments are described in sufficient detail to enableone skilled in the art to practice the disclosure, it is understood thatthese examples are not limiting, such that other embodiments may beused, and changes may be made without departing from the spirit andscope of the disclosure.

The present disclosure relates in various embodiments to features,apparatuses, systems, and methods for the rapid layout and installationof interior walls during building construction. The disclosedembodiments can be used to speed up the layout process by eliminatingsome of the steps traditionally used in this process. In particular, thedisclosed embodiments can utilize specialized anchors, clasps, modifieddrywall tracks, and other components to render as unnecessary at leastthe traditional steps of creating measurement lines along a floor,snapping related chalk lines along the edge of a wall, and transferringthose chalk lines to structural elements in a ceiling.

Rather than precisely affixing drywall tracks to an existing structuralcomponent using previously drawn lines in a traditional manner, thelayout process of the present disclosure involves precisely affixinganchors, locator pin assemblies, or other similar anchoring features tothe structural component and then coupling the drywall track to theanchors. The precise locating and installing of anchors can be easierthat the precise drawing of chalk lines, since only points are needed tobe located for the anchors, which can be readily and quickly installedonce the points are located. The drywall track can be modified toinclude clasps or other anchor attachment components affixed to thetrack around openings therethrough so as to facilitate a quick but firmsnap on attachment of the modified drywall track to the alreadyinstalled anchors. The drywall track can be modified as needed at theconstruction site or can be modified previously off site, which canprovide additional advantages.

Although various embodiments disclosed herein discuss specific anchors,clasps, and locator pins, it will be readily appreciated that thedisclosed features, apparatuses, systems, and methods can similarly beused for any relevant interior wall layout and installation process thatuses anchoring components to install drywall tracks to eliminate theneed for drawing chalk lines. Also, while the exemplary apparatuses,system, and methods are provided with respect to drywall track layoutfor the formation of interior walls in building construction, it will bereadily appreciated that the provided apparatuses, systems, and methodscan also be used with respect to the attachment of studs, pipe hangers,duct hangers, cable tray hangers, wood beams, and other components toceilings, floors, and any other structural items in the formation of anytype of building structure, as well as other alternative embodiments.

Overall Layout System

Referring first to FIG. 1A, exemplary anchor locations along a ceilingas determined by a robotic total station are illustrated in topperspective view. Anchor location point arrangement 1 can involve, forexample, anchor points 2 that are located along a ceiling 31 or otherstructural component where anchors 10 are to be attached. The anchorpoints 2 can be precisely located using a robotic total station 71,which can be placed on a floor 72 or at any other suitable location. Insome arrangements, anchor points 2 can be marked for later attachment ofanchors 10. Alternatively, each anchor 10 can be readily and easilyinstalled at each anchor point 2 while the robotic total station 71 isindicating the anchor point locations. Anchors 10 can be installed byway of fasteners 3, which can be powder actuated fasteners, for example,or alternatively nails, screws, or any other suitable fastener. Byattaching the anchors 10 to the ceiling 31 with fasteners 3 in thismanner, an installer avoids the need to mark floors, ceilings, walls,and/or other structural items with chalk lines.

Continuing with FIG. 1B, an exemplary drywall track configured to mountto anchors at the anchor locations is also shown in top perspectiveview. Structural arrangement 5 can include the same ceiling 31 or otherstructural component shown in FIG. 1A, as well as the anchors 10 andfasteners. Although shown as exploded for purposes of illustration,anchors 10 can be installed at ceiling 31 already if such installationoccurred when the robotic total station was indicating the anchor pointlocations. Drywall track 40 can be modified to have openings 41, 42configured to fit over the installed anchors 10, and lock into place onthe anchors, as set forth in greater detail below. Because the drywalltrack 40 readily and quickly locks onto the installed anchors in amanner that also aligns the track, the installer can also avoid thetraditional need to align the track to layout chalk lines or marks byeye.

Anchor

Transitioning now to individual system components, FIG. 2A illustratesin front perspective view an exemplary anchor configured for rapidconstruction according to one embodiment of the present disclosure.Anchor 10 can include a lower portion 11 configured to couple with anexisting building structure, such as a ceiling, floor, or other buildingcomponent. Lower portion 11 can include a bottom surface 12, which canbe substantially flat to lie flush against the existing buildingstructure. Lower portion 11 can also include one or more exteriorsurfaces, such as a single circular exterior surface as shown, and thisexterior surface can fit within an opening in a separate drywall track,as detailed below. Lower portion 11 can also include a tapered region 9,which tapered region 9 helps to align a separate drywall track onto theanchor 10 as the separate drywall track is installed onto the anchor 10.

Anchor 10 can also include an upper portion 13 located proximate thelower portion 11. In some arrangements upper portion 13 and lowerportion 11 can essentially form the entire anchor 10. Upper portion 13can have a top surface 14 and an external notch 15 that is configured toreceive a separate clasp that holds the separate drywall track in placeagainst the anchor, as detailed below. Upper portion 13 can also includeone or more exterior surfaces, such as a single circular surface asshown. Anchor 10 can also include a central opening 16 that extendsthrough the lower portion 11 and upper portion 13. This central opening16 can be configured to receive a fastener (e.g., a powder-actuatedfastener) that extends through the anchor 10 and into the existingbuilding structure to hold the anchor 10 in place against the existingbuilding structure. In some arrangements, the fastener can be combinedwith the anchor 10 to form a single component. This can involve couplingthe fastener to the anchor, such as by way of a threaded matingarrangement, or by creating a singular integrally formed anchor-fastenercombination.

Central opening 16 can include a tapered region 17 through the upperportion 13, as this can facilitate a firm attachment of the anchor 10 tothe existing building structure using a fastener that mates well withthe geometry of the tapered region 17. In various embodiments, theentire anchor 10 can be symmetrical about a longitudinal axis 18 thatthat extends through the length of the central opening 17. This symmetrynot only facilitates an easier installation of the anchor 10 due to allrotational orientations being identical, but also allows for ease inanchor formation or manufacture. In fact, upper portion 13 can beintegrally formed with lower portion 11, such that anchor 10 can beformed by a simple process from a single material. For example, anchor10 can be formed by cold-forming or machining a metal such as steel.

FIGS. 2B and 2C show anchor 10 in side elevation and top plan viewsrespectively. These views simply provide different perspectives for thelower portion 11, upper portion 13, central opening 16 and variousfeatures thereof. FIG. 2D illustrates anchor 10 in side cross sectionview. Here, it is easier to see the relative geometries and dimensionsof lower portion 11, upper portion 13, external notch 15, and centralopening 16. Again, bottom surface 12 can be substantially flat when itis intended to couple with a flat substrate of an existing buildingstructure. Alternatively, bottom surface 12 can have a shape that isspecifically designed to couple well with an irregular substrate havinga non-flat surface region.

As shown, central opening 16 can have one cross-sectional diameter atlower portion 11 and another larger cross-sectional diameter at upperportion 13. The cross-sectional diameter of central opening 16 canlinearly decrease in size through at least part of upper portion 13,such that anchor 10 can mate well with flat head type fasteners insertedtherethrough. As such, anchor 10 can be configured to receive afastening force from a flat head type fastener at the inner surface ofcentral opening 16 where the cross-sectional diameter of the centralopening linearly decreases in size (i.e., at the tapered region of thecentral opening 16). Alternatively, or in addition, anchor 10 can beconfigured to receive a fastening force from a fastener at the topsurface 14 of upper portion 13. This can depend on the type of fastenerused, which can involve a bolt type fastener having a head with an upperflange.

External notch 15 can define an annular (i.e., ring shaped) groove theextends around the outer circumference of upper portion 13. Whileexternal notch 15 is located at upper portion 13 for purposes ofillustration, it will be understood that this notch or a similarlyfunctional clasp locking feature can be located elsewhere at anchor 10.For example, external notch 15 can be located at lower portion 11,between the upper and lower portions, or at any other external orinternal surface that is designed to interact with a separate clasp orlocking component. Again, external notch 15 can be symmetrical, suchthat it can be locked onto by a separate clasp regardless of therotational orientation of anchor 10. This can allow for ease ininstallation since no concern is needed as to the anchor orientation.External notch 15 can be sufficiently deep or sharply defined to as toprevent the separate clasp from slipping off once it has locked onto thenotch. Further, top surface 14 can have an outer chamfer or rounded edgeto facilitate movement of the clasp arms during clasp installation, asset forth in greater detail below.

FIG. 2E illustrates in side cross section view an exemplary alternativeanchor according to one embodiment of the present disclosure. Anchor l0a can be substantially similar to anchor 10 above, with the exception ofthe central opening geometry. Rather than have a smooth surfaced centralopening, anchor l0 a can have a threaded central opening 19. As will bereadily appreciated, this threaded central opening 19 can be configuredto mate with a threaded fastener, such as a threaded screw, bolt, or thelike. Where such a threaded fastener is used with a threaded centralopening 19, the load through the fastener can be distributed through theanchor threads as well as the top surface of the anchor upper portion.This alternative anchor l0 a can be particularly useful where the anchorand fastener are to be combined as a single component prior toinstallation.

Clasp

Continuing with another individual system component, FIG. 3A illustratesan exemplary clasp for use with a drywall track in front perspectiveview. Clasp 20 can be a spring clasp that is configured to lock onto theexternal notch of an anchor and hold a drywall track in place againstthe anchor. Clasp 20 can be punch formed from sheet metal, for example,and can include a base 21 and arms 22 that are pivotally coupled todistal ends of the base 21. Arms 22 can be configured to pivot outwardwhen the clasp 20 is fitted over the top surface of the upper portion ofthe anchor, and then pivot back inward when the clasp 20 locks onto theexternal notch. Tabs 23 that extend inward from both of the arms 22 canlock into the external notch when the arms 22 pivot back inward.

Clasp 20 can also include flanges 24 that extend laterally from the base21 and both arms 22. The flanges 24 can all include openings 25, 26configured to receive fastening components that affix the clasp 20 to aseparate drywall track. Base flange 24 can include a circular opening25, while the arm flanges 24 can include oval shaped openings 26 thatallow the arms 22 to pivot outward and inward. The fastening componentsthat affix the clasp to the drywall track can be rivets, for example. Aswill be readily appreciated, clasp 20 can be spring biased for the armsto pivot inward, such that the arms 22 readily pivot inward after theclasp has been fitted onto an anchor. FIGS. 3B through 3D show clasp 20in front elevation, top plan, and side elevation views respectively.These views provide further perspectives for the base 21, arms 22, tabs23, flanges 24, and openings 25, 26.

Modified Drywall Track

FIGS. 4A and 4B illustrate an exemplary drywall track in frontperspective and top plan views respectively. Drywall track 40 a can be atraditional unmodified drywall track for use in the formation ofinterior walls. As is generally well known, drywall track 40 a candefine a base and two sides formed from any suitable material, such asgalvanized steel. Although a simple U-shaped drywall track 40 a is shownfor purposes of illustration, it will be appreciated that virtually anysize, shape, type, and material of standard drywall track can be used inconjunction with the various embodiments provided herein. In fact, theactual standard drywall track used merely needs to be compatible for themodifications presented herein. In particular, any standard drywalltrack that can be modified to form two openings within the base to affixtwo clasps thereto can be used.

FIG. 4C illustrates in top plan view an exemplary drywall track modifiedto have two openings formed therein according to one embodiment of thepresent disclosure. Oval or slot opening 41 can be formed in the basetoward one end of drywall track 40, while circular opening 42 can beformed in the base toward the other end of drywall track 40. Thedistance between these openings 41, 42 can be specified as desiredaccording to the length of the drywall track 40 and the design of theexisting building structure to which the track is to be mounted.Further, the actual length of the drywall track 40 can be cut to aspecific length according to the existing building structure design aswell. As will be readily appreciated, the use of a slot or oval for slotopening 41 can allow for a slight amount of distance misalignment ortolerance stackup in the distance between the openings 41, 42 and thedistance between anchors that are already installed into an existingbuilding structure.

Continuing with FIG. 5A, the modified drywall track of FIG. 4C is shownin top perspective view with two clasps attached around the twoopenings. Assembled combination 50 can include modified drywall track 40having openings 41, 42, as well as clasps 20 affixed to the drywalltrack around the openings. Three rivets 27 can be used to affix eachclasp 20 to the drywall track 40 using the flanges on the clasps. Eachclasp 20 can be affixed to drywall track 40 around its respectiveopening 41, 42 as shown, such that anchors that are already installedinto an existing building structure can fit through the openings 41, 42and have the clasps 20 lock onto the external notches on the anchors.

FIGS. 5B and 5C illustrate assembled combination 50 in top plan view andbottom plan view respectively for additional perspectives. As shown forpurposes of illustration, rivet 27 a can fasten base flange 24 a ofclasp 20 to the base of drywall track 40, while rivets 27 b and 27 c canfasten arm flanges 27 b and 27 c respectively While rivets 27 a maytightly fasten clasp 20 to drywall track 40, it can be favorable forrivets 27 b and 27 c to fasten the clasp 20 to drywall track loosely toallow the arms of clasp 20 to pivot outward and inward freely. Bothclasps 20 may be similarly fastened to the drywall track 40. As shown,tabs 23 on each clasp are positioned about openings 41, 42 to facilitatelocking onto the external notches of anchors during track installation.

Turning next to FIG. 6A, an exemplary clasp is shown in frontperspective view prior to locking onto an installed anchor. Arrangement60 depicts a single clasp 20 having tabs 23 that have just started tocontact the top surface 14 of anchor 10. As such, clasp arms 22 arestarting to pivot outward so that the entire combination of clasp 20 anddrywall track 40 can push onto anchor 10. As shown, anchor 10 hasalready been inserted through opening 42 in drywall track 40, and anchor10 can already be affixed previously to an existing building structure(not shown) by way of fastener 3. FIG. 6B illustrates the exemplaryclasp after locking onto the anchor. In arrangement 61, tabs 23 haveslid past the top part of upper portion 13 to lock onto external notch15 when arms 22 pivot back inward.

FIG. 7 illustrates in top perspective view the modified drywall track ofFIG. 5A after installation onto two anchors. Arrangement 70 reflects afinal installation of drywall track 40 onto an existing buildingstructure (not shown), such as a ceiling, floor, or other structuralcomponent. As shown, two clasps 20 have been fastened to the drywalltrack 40 as detailed above, and the drywall track and clasp combinationhas been installed onto two anchors 10 that have already been installedinto the existing building structure. Alignment of arrangement 70 duringinstallation is aided by the tapered regions of the anchors 10 when thedrywall track openings are placed over the anchors 10. When allcomponents are formed and installed in the manner set forth above, thedrywall track and clasp combination can quickly and simply snap onto theinstalled anchors.

Alternative Layout System

Although the foregoing system involving anchors, clasps, and modifieddrywall tracks works well, other ways of using anchoring devices toreduce time and effort in the interior wall layout and installationprocess are also possible. One such alternative arrangement is providedin FIGS. 8-14, as detailed below.

FIG. 8 shows an exploded view of locator pin assembly 100. The assemblyconsists of a bushing 110, annular spring clip 120, and pin 130. Bushing110 is made from an impact resistant material such as steel. It featuresa groove 111 along its perimeter and a hole 112 which runs through thez-axis. Annular spring clip 120 is a flat metal spring with three springtabs 121 equally spaced in a circular pattern about the z-axis. It isappreciated that in alternate embodiments, annular spring clip 120 canfeature more than three spring tabs 121. Annular spring clip 120 wrapsaround bushing 110 within groove 111. It is appreciated that inalternate embodiments, bushing 110 and annular spring clip 120 can beconsolidated into a single part. Pin 130 is an impact-resistant steelpin which features a pointed tip 131 and a flat head 132. The pointedtip 131 aids embedment into a substrate, and the flat head 132 allowsthe pin to be driven by a nail gun. Pin 130 fits through hole 112 inbushing 110 with a friction fit.

FIG. 9 provides an elevation view of locator pin assembly 100. Bushing110 grips pin 130 with a friction fit slightly below pointed tip 131.FIG. 10A provides an elevation view of locator pin assembly 100 as aninstaller prepares to drive it into a substrate 310. In this view, theinstaller has loaded locator pin assembly 100 into a nail gun 320, suchthat nozzle 321 of nail gun 320 fits over pin 130 and presses againstthe bottom of bushing 110. The operator has aligned pointed tip 131 ofpin 130 to a predetermined position against substrate 310. Substrate 310can represent a variety of potential ceiling and floor materials, suchas concrete, steel, and wood. FIG. 10B provides an elevation view oflocator pin assembly 100 at the moment when the top surface of bushing110 impacts the surface of substrate 310. By actuating nail gun 320, theoperator imparted an axial force onto locator pin assembly 100, causingpointed tip 131 to fully breach the surface of substrate 310. At theinstant when bushing 110 impacts substrate 310, bushing 110 comes torest. At the same time, pin 130 overcomes the force of friction withbushing 110 and continues its path into substrate 310. FIG. 10C providesan elevation view of locator pin assembly 100 at the moment when flathead 132 of pin 130 impacts bushing 110, causing pin 130 to come to astop. At this time, pin 130 is fully embedded into substrate 310.

FIG. 11 provides an exploded view of metal wall track 400 which isconfigured to snap over a pair of locator pin assemblies 100 embedded insubstrate 310. Metal wall track 400 has a U-shaped profile, wherehorizontal section of the profile is called web 410. Web 410 containstwo dimples 411, which are positioned at opposing ends of the part. Thefirst dimple 411 contains a round hole 412, and the second dimple 411contains an obround hole 413. Captive washers 420 fit into round hole412 and obround hole 413 from below. Retention rings 430 engage captivewashers 420 from above and are fastened to captive washers 420 duringthe manufacturing process using screws, welds, and the like. When eachretention ring 430 mates to its corresponding captive washer 420, itsandwiches web 410 against captive washer 420. At round hole 412,captive washer 420 is fixed in a concentric position with respect toround hole 412. At obround hole 413, captive washer 420 is permitted toslide longitudinally within the limits of obround hole 413. To installmetal wall track 400 to substrate 310, the installer positions metalwall track 400 under the locator pin assemblies 100 such that captivewashers 420 align concentrically with locator pin assemblies 100. Thelongitudinal freedom of captive washer 420 within obround hole 412allows the installer to precisely match the spacing of locator pinassemblies 100 in substrate 310, within the tolerance band dictated bythe center-to-center dimension of obround hole 412.

FIG. 12 shows a cross section view of metal wall track 400 as theinstaller presses metal wall track 400 over locator pin assemblies 100.At this moment, there is a distance d between wall track 400 andsubstrate 310. As metal wall track 400 travels upward, the insidediameters of captive washers 420 impart radial forces on spring tabs121, causing them to deflect inward. As spring tabs 121 deflect inward,metal wall track 400 is permitted to continue its travel towardsubstrate 310. FIG. 13 shows a cross section view of metal wall track400 at the moment when captive washers 420 snap past the tips of springtabs 121. At this instant, metal wall track 400 is fully seated againstsubstrate 310. Spring tabs 121 have returned to their original position,now spread against the lower surface of captive washers 420 such thatthey clamp metal wall track 400 against substrate 310. FIG. 14demonstrates that the locations of locator pin assemblies 100 along theplane of substrate 310 (i.e. ceiling) can be determined by a robotictotal station 710 positioned on a floor 720. By embedding locator pinassemblies 100 in substrate 310 at these locations, the installer hasavoided the need to mark wall edges with chalk lines. Furthermore,because metal wall track 400 is manufactured to self-align with locatorpin assemblies 100 at these positions, the installer will avoid thetraditional process of aligning metal wall track 400 to layout marks byeye.

Method

Lastly, FIG. 15 provides a flowchart of an exemplary method of attachinga component to an existing building structure. The component can be adrywall track, for example. While method 1000 is specifically directedto a process of using the components set forth in FIGS. 1 through 7B, itwill be readily appreciated that many of the provided steps and detailshere may be similarly applied to the components set forth in FIGS. 8-14.Other steps may be modified or adjusted with respect to these lattercomponents as may be applicable. Although various steps in exemplarymethod 1000 may be performed manually, it will be understood that someor all of the steps may also be automated in some arrangements.

After a start step 1002, first and second openings in a drywall trackmay be formed at process step 1004. This can involve the use of anexisting floor plan, such that the length of the drywall track may bespecified and adjusted accordingly. The openings may then be formed atappropriate locations in the drywall track for proper attachment to adesired building structure. As noted above, one of the openings may becircular while the other forms an extended slot to allow for toleranceor slight measurement offset issues. Continued formation of a customizeddrywall track can then continue at process step 1006, where a firstclasp is coupled to the drywall track. The first clasp can be attachedaround one of the openings by rivets, for example. A second clasp cansimilarly be coupled to the drywall track at process step 1008, such asaround the other opening.

At process step 1010, a first point on the building structure can belocated. This can be done by using a robotic total station as detailedabove. At subsequent process step 1012, a first anchor can then beattached to the existing building structure at the first point. A secondpoint on the existing building structure can similarly be located atprocess step 1014, and a second anchor can be attached to the existingbuilding structure at the second point at subsequent process step 1016.At the following process step 1018, the drywall track can then beinstalled onto the first and second anchors. The method then ends at endstep 1020.

For the foregoing flowchart, it will be readily appreciated that notevery method step provided is always necessary, and that further stepsnot set forth herein may also be included. For example, added steps caninvolve specifying a length of the drywall track, cutting the drywalltrack to the specified length, and/or forming the first and secondclasps out of a sheet metal source, among other possible steps.Furthermore, the exact order of steps may be altered as desired, andsome steps may be performed simultaneously. For example, steps 1004-1008may alternatively be performed after step 1016. Also, steps 1010 and1014 can be performed simultaneously in some embodiments. Not all stepsare always necessary either. For example, steps 1004-1008 may not beperformed in all embodiments, such as where a separate process providespre-formed customized drywall tracks which are then later installed by abuilder who performs all other steps.

Although the foregoing disclosure has been described in detail by way ofillustration and example for purposes of clarity and understanding, itwill be recognized that the above described disclosure may be embodiedin numerous other specific variations and embodiments without departingfrom the spirit or essential characteristics of the disclosure. Certainchanges and modifications may be practiced, and it is understood thatthe disclosure is not to be limited by the foregoing details, but ratheris to be defined by the scope of the appended claims.

What is claimed is:
 1. An anchor configured for rapid construction, theanchor comprising: a lower portion configured to couple with an existingbuilding structure, wherein the lower portion includes a bottom surfaceto contact the existing building structure and one or more exteriorsurfaces that fit within an opening in a separate constructioncomponent; an upper portion located proximate the lower portion andhaving a top surface, wherein the upper portion includes an externalnotch configured to receive a separate clasp that holds the separateconstruction component in place against the anchor; and a centralopening that extends through the lower portion and upper portion,wherein the central opening is configured to receive a fastener thatextends through the anchor and into the existing building structure tohold the anchor in place against the existing building structure.
 2. Theanchor of claim 1, wherein the upper portion is integrally formed withthe lower portion.
 3. The anchor of claim 1, wherein the entire anchoris symmetrical about a longitudinal axis that extends through the lengthof the central opening.
 4. The anchor of claim 1, wherein the separateconstruction component is a drywall track, a pipe hanger, a duct hanger,or a cable tray hanger.
 5. The anchor of claim 1, wherein the anchor isconfigured to receive a fastening force from the fastener at the topsurface of the upper portion.
 6. The anchor of claim 1, wherein thefastener is combined with the anchor to form a single component.
 7. Theanchor of claim 1, wherein the external notch defines an annular groovethat extends around the outer circumference of the upper portion.
 8. Theanchor of claim 1, wherein at least part of the central opening includesan internal thread configured to mate with the fastener.
 9. A systemconfigured for rapid construction, the system comprising: a constructioncomponent having a first opening; and a first clasp coupled to theconstruction component and arranged around the first opening, whereinthe first clasp is configured to lock onto a first external notch of afirst anchor and hold the construction component in place against thefirst anchor.
 10. The system of claim 9, wherein the first claspincludes a base, a first arm pivotally coupled to a first distal end ofthe base, and a second arm pivotally coupled to a second distal end ofthe base opposite the first distal end.
 11. The system of claim 10,wherein the first arm and second arm are configured to pivot outwardwhen the first clasp is fitted over the top surface of the upper portionof the first anchor and to pivot back inward when the first clasp locksonto the first external notch.
 12. The system of claim 11, wherein thefirst clasp further includes tabs extending inward from both of thefirst and second arms, and wherein the tabs lock into the first externalnotch when the first and second arms pivot back inward.
 13. The systemof claim 11, wherein the first clasp further includes flanges thatextend laterally from the base, the first arm, and the second arm, andwherein the flanges include openings configured to receive fasteningcomponents that affix the first clasp to the construction component. 14.The system of claim 9, wherein the construction component is a drywalltrack, a pipe hanger, a duct hanger, or a cable tray hanger.
 15. Thesystem of claim 9, wherein the construction component includes a secondopening, the system further comprising: a second clasp coupled to theconstruction component and arranged around the second opening, whereinthe second clasp is configured to lock onto a second external notch of asecond anchor and hold the construction component in place against thesecond anchor.
 16. The system of claim 15, further comprising: the firstanchor, wherein the first anchor includes a first lower portionconfigured to couple with an existing building structure and one or moreexterior surfaces that fit within the first opening in the constructioncomponent and a first upper portion located proximate the first lowerportion and having a first top surface and the first external notch; andthe second anchor, wherein the second anchor includes a second lowerportion configured to couple with the existing building structure andone or more exterior surfaces that fit within the second opening in theconstruction component and a second upper portion located proximate thesecond lower portion and having a second top surface and the secondexternal notch.
 17. A method of attaching a construction component to anexisting building structure, the method comprising: forming a firstopening in the construction component; and coupling a first clasp to theconstruction component with one or more fastening components such thatthe first clasp is arranged around the first opening, wherein the firstclasp is configured to lock onto a first external notch of a firstanchor and hold the construction component in place against the firstanchor.
 18. The method of claim 17, further comprising the steps of:forming a second opening in the construction component; and coupling asecond clasp to the construction component with one or more fasteningcomponents such that the second clasp is arranged around the secondopening, wherein the second clasp is configured to lock onto a secondexternal notch of a second anchor and hold the construction component inplace against the second anchor.
 19. The method of claim 18, furthercomprising the steps of: locating a first point along the existingbuilding structure using a robotic total station; attaching the firstanchor to the existing building structure at the first point with afirst fastener, wherein the first anchor includes a lower portionconfigured to couple with the existing building structure and one ormore exterior surfaces that fit within the first opening in theconstruction component, an upper portion located proximate the lowerportion and having a top surface and the first external notch, and acentral opening that extends through the lower portion and upperportion; locating a second point along the existing building structureusing the robotic total station; attaching the second anchor to theexisting building structure at the second point with a second fastener,wherein the second anchor fits within the second opening in theconstruction component and includes the second external notch; andinstalling the construction component onto the first anchor and thesecond anchor by placing the first anchor through the first opening andthe second anchor through the second opening, wherein the first clasplocks onto the first external notch to hold the first clasp andconstruction component in place against the first anchor and theexisting building structure and the second clasp locks onto the secondexternal notch to hold the second clasp and construction component inplace against the second anchor and the existing building structure. 20.The system of claim 17, wherein the construction component is a drywalltrack, a pipe hanger, a duct hanger, or a cable tray hanger.